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Miller 252 issue

03-28-2014, 07:29 PM

Decided after running older units for years it was time to purchase a new unit for the home stead.Purchased a new Miller 252, 230/460/575 model, set it for 230volt operation.
The problem is severe excessive splatter, running .035 ms wire with 75% argon 25% Co2 at 20-25 lpm. I can only weld about 8-12 inches before the whole tip closes over from splatter and quits working.
Tried varying volts and wire speed according to owners manual, but with no luck.
Any help would be greatly appreciated.

Decided after running older units for years it was time to purchase a new unit for the home stead.Purchased a new Miller 252, 230/460/575 model, set it for 230volt operation.
The problem is severe excessive splatter, running .035 ms wire with 75% argon 25% Co2 at 20-25 lpm. I can only weld about 8-12 inches before the whole tip closes over from splatter and quits working.
Tried varying volts and wire speed according to owners manual, but with no luck.
Any help would be greatly appreciated.

Comment

i know what you have going on there, its more of a gun issue than any thing else, the gun that comes with the 252 does not like heat. the weldor is real comfortable running hot welds, but the gun cant keep up with the welder, get a different gun is what i did, a bernard q

Comment

Decided after running older units for years it was time to purchase a new unit for the home stead.Purchased a new Miller 252, 230/460/575 model, set it for 230volt operation.
The problem is severe excessive splatter, running .035 ms wire with 75% argon 25% Co2 at 20-25 lpm. I can only weld about 8-12 inches before the whole tip closes over from splatter and quits working.
Tried varying volts and wire speed according to owners manual, but with no luck.
Any help would be greatly appreciated.

Thanks
Lyle

What voltage and ipm are you running?

Check the nuts/lugs on the lead and ground cable. Sounds like a bad ground to me. I'd even grind a spot bear for the ground clamp just to rule it out.

I did go with a 1/2" orifice and 1/8" recessed nozzle. Seems to weld much better.

Don't give up I really like my 252

Comment

You didn't state the material thickness you are using. I used the info you did provide to determine a solution. Looking up weld settings on Millers iphone app this is what I found.
For 20 gauge steel the settings are;
15 - 16 volts
105-115 ipm
You stated you ipm as 20-25. Therefore I'd say you ipm is TOO low.

Comment

Lyle, your info in first post is a bit confusing - if that 20-25 number is inches per minute wire feed, it's 'way too low and could easily cause burnback. If it is really Liters per minute gas flow, it's about 5 TIMES what's required.

If you can clarify EXACTLY what you are welding and what ALL your settings are, it'd be easier to help... Steve

Comment

have you found the welding specs on the machine, there are no door charts on my 252, the specs are kinda hidden on the front close to the top, those specs are very close and they are calibrated for 75/25 mix, un like the older machines which were calibrated for co2, try using what they say, i found on mine that the voltage was a bit high, requiring more ipm,s, but that maybe caused by a high line voltage input to the circuit box from the power on the pole. once you get used to the machine, pay attention as to how it runs during different times of the day, weather/temperature will cause a fluctuation in line voltage. there fore causing a change in settings, but not by much, or any, i just mentioned the line voltage for a FYI. good luck. kevin